Slotted masonry wall structure and metal stud therefor

ABSTRACT

A masonry building block of hollow construction and having at least one surface defining a continuous reversely beveled slot to receive the oppositely diverging resilient flanges of a snap-in metal stud. The vertical studs interfit with upper and lower perimeter channels to form a rigid structure. The studs may be employed to route electrical cable and the like. The studs may be rigidified within the block slots by means of spreader screws.

United States Patent [191 LoCicero 1 Dec. 2, 1975 SLOTTED MASONRY WALL STRUCTURE AND METAL STUD THEREFOR [76] Inventor: James T. LoCicero, 1836 Millard Drive, Madison Heights, Mich. 48071 [22] Filed: Dec. 13, 1973 [21] Appl. No.: 424,353

[52] U.S. Cl. 174/48; 52/221; 52/370; 52/371 [51] Int. Cl. H02G 3/28; E04B 2/00 [58] Field of Search 52/220, 287, 585, 586, 52/608, 221, 370, 371, 372, 375

[56] References Cited UNITED STATES PATENTS 1,421,986 7/1922 Phillips 52/375 3,374,590 3/1968 Kessler 1 52/221 3,377.756 4/1968 Polhamus. 52/220 3545154 12/1970 Bobzin 52/586 3,559,358 2/1971 Lohse 52/509 3,562,988 2/1971 Gregoire. 52/586 X 3,818,665 6/1974 Rogers 52/375 FOREIGN PATENTS OR APPLICATIONS 573,118. 6/1924 France 52/586 Primary Examiner-Frank L. Abbott Assistant ExaminerWilliam Randolph Attorney. Agent, or FirmThomas N. Young [57] ABSTRACT A masonry building block of hollow construction and having at least one surface defining a continuous reversely beveled slot to receive the oppositely diverging resilient flanges of a snap-in metal stud. The vertical studs interfit with upper and lower perimeter channels to form a rigid structure. The studs may be employed to route electrical cable and the like. The studs may be rigidified within the block slots by means of spreader screws.

13 Claims, 5 Drawing Figures US. Patent Dec. 2, 1975 3,924,056

SLOTTED MASONRY WALL STRUCTURE AND METAL STUD THEREFOR INTRODUCTION This invention relates to building structures and more particularly to the combination of a slotted building block and an open channel stud having resilient flanges adapted to be snapped into the slot to form a base for the installation of additional elements, such as paneling, wall board, and so forth.

BACKGROUND OF THE INVENTION The conventional techniques for finishing the surfaces of a masonry block wall involve nailing wood furring strips to the wall or, alternatively, constructing a parallel wall out of two-by-four studs. The latter technique is required wherever the finish surface must be true and plumb and the masonry block wall does not meet these criteria.

It is apparent that the conventional techniques are time consuming and expensive and, at the same time, fail to result in a wall or partition structure which is readily furnished with such accessories as elelctrical wiring for outlets and so forth.

One alternative prior art method of securing panels to masonry blocks is shown in US. Pat. No. 1,567,085 to include the formation of T-shaped slots in the blocks to receive wood studs as nail anchors. In this system, the finish panel rests directly on the block and no provision is made to allow the stud to enter the slot other than by sliding it in from an end thereof. Moreover, no provision is made to firmly anchor the stud in the slot other than by providing a tight fit.

BRIEF STATEMENT OF THE INVENTION The present invention provides a substitute for the aforementioned wood furring strips and parallel wall structures, such alternatives being economical and simple in construction and at the same time resulting in a wall or partition structure which is readily provided with electrical wiring, plumbing, and other accessory installations.

In general, the present invention involves the construction of a block wall, typically masonry, wherein each block has formed therein one or more slots which are adapted to receive relatively resilient flanges of an open channel stud. Accordingly, walls, partitions, or like structures can be fabricated using the slotted blocks, the slots being aligned with one another to form substantially or fully continuous slots after which the studs may be fully or partly disposed in the slots simply by flexing the resilient flanges and snapping them into place. The result is a block wall, partition, or like structure having spaced, parallel studs of a material, such as extruded aluminum, thin wall steel, plastic, or the like, to readily receive fasteners for interior and exterior surface panels, electrical wiring, plumbing and other accessory items.

In accordance with the preferred embodiment of the invention hereinafter described in greater detail, the slots formed in the blocks are characterized by outwardly and oppositely diverging channel walls and the studs are formed of a relatively resilient, thin wall material, such as aluminum, so as to exhibit oppositely outwardly diverging flanges or fingers which may be snapped into the block channels. Spreader means are provided for rigidifying the studs once in place within the block channel. The channels may be of such configuration as to define a projecting box portion which projects outwardly from the surface of the blocks thereby to provide space for installation and other enclosed articles, such as conduit and pipes. The studs are normally vertically disposed and a base channel also of an open-channel configuration may be provided to interfit with the studs for rigidification and receipt of electricalconduit, baseboards, and other structural elements.

The invention will be best understood upon reference to the following specification which describes an illustrative embodiment of the invention in detail. This specification is to be taken with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of a masonry building block having full and partial channels formed therein;

FIG. 2 is a perspective view of a partially constructed wall or partition having at leasat one stud in place;

FIG. 3 is a cross sectional view of the stud and a portion of the block and base channel in the assembly of FIG. 2;

FIG. 4 is a cross sectional view of a stud being flexed and snapped into place within a block channel; and,

FIG. 5 is a perspective view of a detail in the stud construction of the assembly of FIG. 2.

DETAILED DESCRIPTION OF THE SPECIFIC EMBODIMENT FIG. 1 illustrates a building block 10 used to fabricate walls, partitions, and like structures. Block 10 is typically made of a masonry material, such as concrete, but may be constructed of various other materials, such as ceramic, dense polymeric foam, and so forth. Block 10 is of a hollow structure and exhibits conventional bearing or stacking surfaces 12 and 14 and opposite parallel exterior surfaces 16 and 18. End surfaces 20 and 22 are also provided whereby a plurality of the blocks 10 may be laid up in end-to-end relation to form a tier or course. It is to be understood that the term exterior as used herein refers to the outside surfaces of block l0 when incorporated into a wall, partition, or like structure and does not necessarily designate the interior or exterior of a building or enclosure of which the particular block forms a part.

Surface 16 has formed centrally therein a shallow, reversely beveled slot 24 characterized by oppositely diverging walls 26 and 28 and extending fully and continuously between the bearing surfaces 12 and 14. Partial slots are formed adjacent the ends 20 and 22 of block 10 and are characterized by reversely beveled wall 30 adjacent end 22 and reversely beveled wall 32 adjacent end 20. The partial slots operate in conjunction with similar partial slots in adjacently disposed blocks 10 to form full slots such that a fully constructed tier or course of blocks 10 exhibits a plurality of uniformly spaced, parallel slots having reversely beveled interior side walls.

As shown in FIG. 2, the blocks 10 in alternate vertically stacked tiers or courses are staggered by one-half the width of a block such that the central slots 24 of one block is aligned with the slot made up of two partial slots in the two blocks immediately above and below. The resulting parallel spaced slots in the wall or structure constructed with the blocks 10 receive elongated 3 metal studs 34 which are fabricated in an open-channel configuration and exhibit oppositely diverging and relatively resilient flanges 36 and 38. The flanges 36 and 38 are dimensioned to register with and fit snugly and closely within the slots 24 such that the flanges, when fully inserted, bear against the sidewalls 26 and 28 of the block channels 24. Studs 34 are illustrated as having a projecting three-sided box portion 40 having sides which are contiguous with the flanges 36 and 38 such that a rigid portion of each stud 34 projects outwardly from surfaces 16 of block in the wall, shown in FIG. 2, by approximately two inches. Varying projection dimensions may be achieved by varying the configuration of the stud. In many cases, little or no projection will be desired while in other cases, a projection of more than two inches may be required.

As shown in FIG. 4, the typical method of stud insulation involves prebuilding the wall or partition from blocks 10 so as to define the continuous channels and then snapping the studs 34 in place by deforming or compressing the sidewalls together. This may be easily done by virtue of the resilient, thin-wall construction of the studs 34. It may be desirable to insert one flange 38 into the slot 24 and use the edge of the block 10 as a reaction surface to compress the other flange of the stud 34 during the insertion process. Obviously, the studs 34 may also be driven into place by sliding them in from an end of the wall where this is available. However, it often occurs that a wall end from which to slide in the studs is not available and, accordingly, the snap-in technique of installation will undoubtedly prevail.

FIG. 3 illustrates a spreader screw 42 which is threadedly engaged with and through one of the sidewalls of the box portion 40 of stud 34 and in abutting engagement with the opposite sidewall. Driving the screw through the threaded engagement sidewall and against the opposite sidewall tends to spread the flanges 36 and 38 snugly against the interior sidewalls 26 and 28 of the channel 24 thereby to rigidify and firmly anchor the stud 34 within the slot or channel. Other spreader or rigidification devices may, of course, be employed.

The stud 34, illustrated in FIG. 2, includes a rectangular aperture 44 in the projecting face of the stud, such aperture being formed by removal of a knock-out blank 44a, shown still in place in FIG. 5. The aperture 44 is provided with recessed fastener surfaces 45 to receive the mounting ears of an electrical outlet box such that a duplex or single-outlet type receptacle may be conveniently mounted on and partially within the stud 34 prior to mounting the finish paneling material on the stud 34. An electrical cable 46 is shown disposed within the interior of the stud 34 and projecting partially from the receptacle aperture 44.

A second aperture 48 is formed in the side surface of the box portion 40 of the stud 34 approximately inches from the bottom, as shown in FIG. 2. This permits the electrical cable 46 to emerge from the stud and to travel across the wall. An open perimeter channel 50 is disposed adjacent and along the base of the wall structure and notched at regular intervals to receive the studs 34 in interfitting relation therewith. Channels 50 also rigidify the mounting foundation for the finish paneling material and facilitate the installation of base boards as will be apparent to those skilled in the art.

Assuming a full stud 34 does not conveniently occur at a corner or wall intersection, support for the finished paneling material in the corner may be provided by insertion of a narrow, open-channel corner stud such as shown at 5 2 into the corner and anchoring such stud within the lowerbase member 50. An upper perimeter channel similar to channel 50 may be provided along the top of the wall to receive the upper ends of the studs 34 and the studs 52. It is to be understood that the subject invention contemplates the finishing of the wall, partition, or structure, shown in FIG. 2, by the addition of an external paneling material, such as plywood or gypsum wallboard, by driving suitable fasteners, including barbed nails and/or screws, through the external paneling material and into the thin wall metal studs 34 and 52. As will be apparent to those skilled in the art, it is now a common practice to employ hollow metal studs in interior partitions and to screw-fasten finish paneling materials to these studs.

The studs 34 are preferably made of a thin walled metal, such as aluminum or steel, and the configuration thereof lend itself to extrusion or sheet stamping and bending. However, the subject invention is not limited to metal materials, but may be taken to include various other materials including hard polymeric materials.

While the slots 24 and flanges 36 and 38 are shown in the illustrative embodiment as being continuous, it is to be understood that both the slots and the flanges may be made discontinuous or intermittent in character to facilitate the snap-in installation. The snap-in stud may also be applied to poured concrete and other types of cast, seamless walls by forming the slot during the casting process. This may be done by means of a disposable pattern which is burned out or otherwise removed after the wall is formed. With respect to blocks 10, it is clear that slots may be formed on both surfaces 16 and 18 in the case of an interior partition or where an exterior design is desired. Clearly, both facade and through-wall applications of the invention are contemplated. A variety of other changes may, of course, be made to the invention as illustrated and, therefore, the described embodiment is not to be construed as limiting in sense.

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:

1. Building apparatus comprising: a building block adapted to be assembled with similar blocks to form a substantially continuous structure, said block being constructed of substantially rigid material and having bearing surfaces and exterior surfaces, at least one of the exterior surfaces having formed therein a slot extending between the bearing surfaces; a relatively thinwall, open channel stud adapted to be snapped into the slot, said stud being of a substantially three-sided configuration to define an exposed box portion and contiguous oppositely flared non-parallel manually deformable resilient flanges which are urged toward one another for installation of the stud into the slot and which are dimensioned to fit resiliently and snugly against the walls of the slot when inserted therein, the box portion and flanges being of such depth as to cause the exposed portion to be spaced from the interior surface of the slot in the block when the stud is fully inserted therein such that the exposed portion of the stud may receive elongated fastener devices therein after installation; and means for spreading the sides of the studs contiguous with the flanges to rigidify the stud within the block. I

2. Apparatus as defined in claim 1 wherein the slot is characterized by oppositely inwardly diverging sidewalls.

3. Apparatus as defined in claim 2 wher in the slot is formed substantially centrally in the block, the block further having partial slots formed in the ends thereof to define additional slots parallel with the central slot when two or more of the blocks are placed end-to-end to construct a wall.

4. Apparatus as defined in claim 3 wherein the partial slots extend fully and continuously between the bearing surfaces.

5. Apparatus as defined in claim 1 wherein the means for spreading is a screw projecting through and in threaded engagement with one of said sides.

6. Apparatus as defined in claim 1 including apertures formed within the stud.

7. Apparatus as defined in claim 1 including a perimeter channel adapted to be interfit with the stud at right angles thereto and extending along said block.

8. Apparatus as defined in claim 1 wherein the block is constructed of a masonry material.

9. A building structure comprising: a wall, a plurality of parallel, continuous slots formed in the wall at spaced intervals; a plurality of open channel studs having relatively resilient, oppositely diverging manually resiliently deformable, non-parallel flanges disposed in the slot to serve as anchors for panels to be secured to said wall, said stud having an exposed surface which is contiguous with the flanges and which is substantially parallel to the wall when the stud is disposed in the slot, the exposed portion being spaced from the interior of the slot after installation so as to receive elongated fastener devices therein; and spreader means in the studs and secured to one flange and extending into contact with the other flange and being adjustable to spread the flanges to rigidify the studs in the slots.

10. A structure as defined in claim 9 including electrical outlet means carried by a stud, and electrical conductor means routed through said stud for said outlet means.

11. A structure as defined in claim 10 including a base channel extending along the base of the wall and notched to receive and interfit with said studs.

12. A structure as defined in claim 9 wherein the wall is formed of stacked masonry blocks.

13. A building structure comprising: a masonry block wall including plural courses of masonry blocks resting on the bearing surfaces of one another to form a continuous vertical wall surface; each of said blocks having formed in a surface thereof a shallow slot having oppositely inwardly diverging walls terminating in an interior surface and extending fully between said bearing surfaces, the blocks of said courses being arranged with the slots of adjacent blocks in alignment to form a continuous slot over substantially the entire vertical extent of said wall; and a thin-wall, metal stud of substantially greater length than the height of a block in said wall, said stud forming a three-sided open channel of which two sides terminate in web flanges, the terminal portions of which are fixed outwardly, said channel being resiliently flexible as to be manually flexed together to permit said flanges to be snapped into the slot for installation thereof, and dimensioned to fit snugly within said slot to spring out and lie against the diverging walls thereof between the wall surface and the rear surface of the slot; said stud being dimensioned to protrude outwardly from said wall surface when in place in said slot to receive and support finish panelling material in spaced relation to said masonry wall. 

1. Building apparatus comprising: a building block adapted to be assembled with similar blocks to form a substantially continuous structure, said block being constructed of substantially rigid material and having bearing surfaces and exterior surfaces, at least one of the exterior surfaces having formed therein a slot extending between the bearing surfaces; a relatively thin-wall, open channel stud adapted to be snapped into the slot, said stud being of a substantially three-sided configuration to define an exposed box portion and contiguous oppositely flared non-parallel manually deformable resilient flanges which are urged toward one another for installation of the stud into the slot and which are dimensioned to fit resiliently and snugly against the walls of the slot when inserted therein, the box portion and flanges being of such depth as to cause the exposed portion to be spaced from the interior surface of the slot in the block when the stud is fully inserted therein such that the exposed portion of the stud may receive elongated fastener devices therein after installation; and means for spreading the sides of the studs contiguous with the flanges to rigidify the stud within the block.
 2. Apparatus as defined in claim 1 wherein the slot is characterized by oppositely inwardly diverging sidewalls.
 3. Apparatus as defined in claim 2 wherein the slot is formed substantially centrally in the block, the block further having partial slots formed in the ends thereof to define additional slots parallel with the central slot when two or more of the blocks are placed end-to-end to construct a wall.
 4. Apparatus as defined in claim 3 wherein the partial slots extend fully and continuously between the bearing surfaces.
 5. Apparatus as defined in claim 1 wherein the means for spreading is a screw projecting through and in threaded engagement with one of said sides.
 6. Apparatus as defined in claim 1 including apertures formed within the stud.
 7. Apparatus as defined in claim 1 including a perimeter channel adapted to be interfit with the stud at right angles thereto and extending along said block.
 8. Apparatus as defined in claim 1 wherein the block is constructed of a masonry material.
 9. A building structure comprising: a wall, a plurality of parallel, continuous slots formed in the wall at spaced intervals; a plurality of open channel studs having relatively resilient, oppositely diverging manually resiliently deformable, non-parallel flanges disposed in the slot to serve as anchors for panels to be secured to said wall, said stud having an exposed surface which is contiguous with the flanges and which is substantially parallel to the wall when the stud is disposed in the slot, the exposed portion being spaced from the interior of the slot after installation so as to receive elongated fastener devices therein; and spreader means in the studs and secured to one flange and extending into contact with the other flange and being adjustable to spread the flanges to rigidify the studs in the slots.
 10. A structure as defined in claim 9 including electrical outlet means carried by a stud, and electrical conductor means routed through said stud for said outlet means.
 11. A structure as defined in claim 10 including a base channel extending along the base of the wall and notched to receive and interfit with said studs.
 12. A structure as defined in claim 9 wherein the wall is formed of stacked masonry blocks.
 13. A building structure comprising: a masonry block wall including plural courses of masonry blocks resting on the bearing surfaces of one another to form a continuous vertical wall surface; each of said blocks having formed in a surface thereof a shallow slot having oppositely inwardly diverging walls terminating in an interior surface and extending fully between said bearing surfaces, the blocks of said courses being arranged with the slots of adjacent blocks in alignment to form a continuous slot over substantially the entire vertical extent of said wall; and a thin-wall, metal stud of substantially greater length than the height of a block in said wall, said stud forming a three-sided open channel of which two sides terminate in web flanges, the terminal portions of which are fixed outwardly, said channel being resiliently flexible as to be manually flexed together to permit said flanges to be snapped into the slot for installation thereof, and dimensioned to fit snugly within said slot to spring out and lie against the diverging walls thereof between the wall surface and the rear surface of the slot; said stud being dimensioned to protrude outwardly from said wall surface when in place in said slot to receive and support finish panelling material in spaced relation to said masonry wall. 